Packaging body for honeycomb structure

ABSTRACT

A packaging body for a honeycomb structure including two trays formed with a pocket having a shape complementary to an end face portion of a honeycomb structure and a shallow box-like tray pack surrounding from the outside and containing the one on the side of a lower end face portion of the honeycomb structure of the two trays, the packaging body for a honeycomb structure enables a lateral access from a side (side face) so that a robot arm and hand can easily put in or take out the honeycomb structure.

TECHNICAL FIELD

The present invention relates to a packaging body for a honeycomb structure that is easy to make a lateral access on the occasion when a honeycomb structure is put in or on the occasion when a honeycomb structure is taken out.

BACKGROUND ART

As a catalyst or a filter for automobile exhaust gas purification, a columnar honeycomb structure is used that has a circular or elliptical shape in a cross section perpendicular to the axial direction. On the occasion of shipping of such a honeycomb structure as a product, works of packaging a honeycomb structure so as to be easily transported and to be able to be stored with no damages. In addition, at the time of packaging, conventionally, in general, a packaging box that is manufactured using materials such as plastics or corrugated cardboards is used as a packaging body.

Incidentally, as a prior document related to packaging of a honeycomb structure, there is Patent Document 1.

[Patent Document 1] JP-A-1997-226837

DISCLOSURE OF THE INVENTION

In the case in which a packaging body is a box, due to that there is present a side face that is integral with a bottom face, an advantage arises in that the side faces act as a wall, and a honeycomb structure having been packaged is stable during transportation and protected during being stored and workers can easily handle the packaging body. Owing to that the packaging body is a box, however, a problem exists in that on the occasion when the honeycomb structure is put in (that is, packaged) or when the packaged honeycomb structure is taken out of the packaging body, it is hard to be automated. The reason thereof is that since an access when a honeycomb structure is put in or taken out is limited to the top because it is a box, a general-purpose robot arm and hand are hard to hold the honeycomb structure.

The present invention has been made in view of the above-described situations, and has an object of providing a packaging means enabling the processing from the side (the side face) of a packaging body (it is referred to as a lateral access) so as to make it easy for a robot arm and hand to put a honeycomb structure in a packaging body and to take it out of the packaging body. As a result of amounts of studies, the use of a packaging body described hereinafter is found to be able to achieve the object.

That is, first, according to the present invention, provided is a packaging body for a honeycomb structure (it is referred to as a first packaging body for a honeycomb structure according to the present invention as well), being a packaging body for packaging a honeycomb structure having a columnar shape, comprising:

at least two trays having a plate shape and in which a pocket having a cylindrical shape or an elliptic cylindrical shape is formed; and

a shallow box-like tray pack that surrounds from the outside and contains at least one tray of at least two trays.

In the first packaging body for a honeycomb structure according to the present invention, it is preferable that the tray pack can contain a plurality of the trays. This, in the first packaging body for a honeycomb structure according to the present invention, means that with respect to one tray pack, there is provided a plurality of trays. According to this preferred mode, it is possible that in one tray pack, via a plurality of trays, a number of honeycomb structures can be contained.

In the first packaging body for a honeycomb structure according to the present invention, it is preferable that the tray pack is a formed body which material is paper. As a typical one, there can be corrugated cardboards having cushioning characteristics.

The shallow box-like tray pack surrounds from the outside and contains, for example, a tray containing a lower end face portion of a honeycomb structure. A shallow box shape is a form of a shallow box, and can be represented to be the one in which low walls stand up at peripheral edges of a flat plate or to be a shape such as a tray to be used at home. This tray pack is the one that surrounds from the outside and contains a tray, so that the inside shape of the shallow box can be complementary to the shape of a tray, and, for example, a rectangular shape can be adopted as a planar shape of the inside shape of the tray pack and the outside shape of the tray.

When a honeycomb structure is packaged using the first packaging body for a honeycomb structure according to the present invention, each of the honeycomb structures is secured in each tray at its upper end face portion and lower end face portion, and on the side of the lower end face portion, further, the honeycomb structure is contained in the tray pack as is in the tray. When a honeycomb structure is packaged using the first packaging body for a honeycomb structure according to the present invention, on the side of the side face in the packaged state, being on the side of the peripheral face of the honeycomb structure, there is present no member related to packaging, to be open. As is described below, although there can be further provided a protective member surrounding from the side the honeycomb structures having been packaged, even in the case of including a protective member, the protective member is not the one to form a box integrally with a tray and a tray pack, to be easily removable, and not to impede a lateral access.

Furthermore, as is necessary, in case where the tray on the side of the upper end face portion of the honeycomb structure and the tray pack on the side of the lower end face portion are tied up using e.g., a band and secured, it comes to be possible to hold and transport the tray pack without the touch with the honeycomb structures. On the occasion of being tied up using the band, it is preferable to put on a platy cover that is made of, for example, corrugated cardboards having cushioning characteristics on the top of the tray on the side of the upper end face portion of the honeycomb structure. The reason is that it becomes easy to secure a tray, a tray pack and the entire honeycomb structures having been packaged thereby, as well as a tray comes unlikely to be damaged.

A tray pack is the one to surround from the outside and contain at least one of two trays, and it is preferable to be in a mode in which there are provided two tray packs, and both the tray containing the upper end face portion of the honeycomb structure and the tray containing the lower end face portion of the honeycomb structure are surrounded from the outside and contained. In this mode, a platy cover that is made of corrugated cardboards to be put on the top of the tray on the occasion of being tied up using a band is unnecessary. The reason is that it is a mode in which the two trays sandwiching the honeycomb structures and supporting them are further sandwiched from the outside using the two tray packs, so that in case where these two tray packs are tied up using e.g., a band on the outside, a tray, a tray pack and the entire honeycomb structures having been packaged thereby can be easily secured, e.g., a band is not brought in contact with the trays, and there are no damages of the trays.

Now, according to present invention, provided is a packaging body for a honeycomb structure (it is referred to as a second packaging body for a honeycomb structure according to the present invention as well), being a packaging body for packaging a honeycomb structure having a columnar shape, comprising

at least three trays having a plate shape and in which a pocket having a cylindrical shape or an elliptic cylindrical shape is formed at one face or at both faces,

wherein a tray having the pocket at one face is disposed in the uppermost layer and in the lowermost layer, and a tray having the pocket at both faces is disposed at an intermediate portion.

Here, the uppermost layer and the lowermost layer indicate a positional relationship with only trays. In a mode in which there is provided a pallet as is described below, in some cases, a pallet may be positioned in the uppermost layer or in the lowermost layer in a packaging body (whole).

Incidentally, in the present specification, when it is merely referred to as a packaging body for a honeycomb structure according to the present invention, it indicates both the first packaging body for a honeycomb structure according to the present invention and the second packaging body for a honeycomb structure according to the present invention.

In the second packaging body for a honeycomb structure according to present invention, it is preferable to further comprise a pallet to be in contact with one face of at least one tray of the trays, wherein the pallet and the one tray are brought in engagement by having a mode in which:

(a) there is provided at the pallet a plurality of concave parts or convex parts and there is provided at the one tray a plurality of convex parts or concave parts, and the concave parts and the convex parts of the pallet are loosely fit to the convex parts and the concave parts of the one tray, or

(b) there is provided in the pallet and the one tray a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to the concave parts that are formed in the pallet and the one tray.

In the mode of (a), for example, in wood machining, a convex part serves to be a tenon and the concave part serves to be a mortice, and a pallet and a tray are brought in engagement. However, the second packaging body for a honeycomb structure according to the present invention is a packaging body and needs to be easily disassembled, so that it is necessary that the convex part is loosely fit to the concave part. In addition, in the mode of (b), for example, in wood machining, the joining member serves to be a dowel and the concave part serves to be a dowel hole, and a pallet and a tray are brought in engagement. However, the second packaging body for a honeycomb structure according to the present invention is a packaging body and needs to be easily disassembled, so that it is necessary that the joining member is loosely fit to the concave part.

In the second packaging body for a honeycomb structure according to the present invention, it is preferable that the two trays of the trays are brought in engagement by having a mode in which:

(1) there is formed a plurality of concave parts in one tray of the two trays and there is provided at the other tray a plurality of convex parts, and the concave parts of the one tray and the convex parts of the other tray are brought in a loose fit, or

(2) there is provided in each of the two trays a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to the concave parts formed in each of the two trays.

In the mode of (1), for example, in wood machining, a convex part serves to be a tenon and the concave part serves to be a mortice, and two trays are brought in engagement. However, the second packaging body for a honeycomb structure according to the present invention is a packaging body and needs to be easily disassembled, so that it is necessary that the convex part is loosely fit to the concave part. In addition, in the mode of (2), for example, in wood machining, the joining member serves to be a dowel and the concave part serves to be a dowel hole, and two trays are brought in engagement. However, the second packaging body for a honeycomb structure according to the present invention is a packaging body and needs to be easily disassembled, so that it is necessary that the joining member is loosely fit to the concave part.

A packaging body for a honeycomb structure according to the present invention is for use in packaging honeycomb structures that is a columnar-shaped body standing (axial direction of the columnar-shaped body is made to be in a vertical direction). A tray has a plate shape in its entirety and formed with a pocket having a shape that is complementary to an end face portion of the honeycomb structure; and, for example, an end face portion on the lower side (it is referred to as a lower end face portion as well) of the honeycomb structure is contained in a pocket of one tray of the two trays and, for example, an end face portion on the upper side (it is referred to as an upper end face portion as well) of the honeycomb structure is held in a pocket in the other tray, and the honeycomb structure is sandwiched between these two trays to be supported. The end face portion of the honeycomb structure is a three-dimensional portion including an end face and a side face in the proximity of the end face.

In a packaging body for a honeycomb structure according to present invention, it is preferable that at one face (at one face or at the other face) or at both faces of the tray having the plate shape, there is formed a plurality of pockets. In this mode, it is possible that between the two trays sandwiching the honeycombs structures, a plurality of honeycombs structures can be contained.

In a packaging body for a honeycomb structure according to the present invention, it is preferable that the tray is a formed body which main material is any of polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride, iron and aluminum. In the case in which a tray is made of plastic materials such as polypropylene, polyethylene or polyethylene terephthalate, it is preferable that the thickness thereof is about 0.3 mm to 2.0 mm.

Next, according to the present invention, provided is a packaging body for a honeycomb structure acting to package a honeycomb structure, being a packaging body for packaging a honeycomb structure having a columnar shape, comprising

at least two trays having a plate shape and in which a pocket having a shape complementary to an end face portion of the honeycomb structure is formed at one face,

wherein an end face portion of the honeycomb structure is fit in each pocket of two trays of at least two trays, and a honeycomb structure is packaged; and

wherein the two trays are brought in engagement by having a mode in which:

(x) there is formed a plurality of concave parts in one tray of the two trays and there is provided at the other tray a plurality of convex parts, and the concave parts of one tray and the convex parts of the other tray are brought in a loose fit, or

(y) there is provided in each of the two trays a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to the concave parts formed in each of the two trays.

In a packaging body for a honeycomb structure acting to package a honeycomb structure according to the present invention, it is preferable to further comprise a protective member surrounding the honeycomb structure and the tray to which an end face portion of the honeycomb structure is fit from the side of the honeycomb structure.

In a packaging body for a honeycomb structure acting to package a honeycomb structure according to present invention, it is preferable that the protective member has a plate shape or a film shape. An example of a platy protective member can include corrugated cardboards (papers) having cushioning characteristics, and an examples of a film-like protective member can include a plastic film or sheet which main material is polypropylene, polyethylene, polyethylene terephthalate and vinyl chloride

The first packaging body for a honeycomb structure according to the present invention is the one comprising: at least two trays in which a pocket having a cylindrical shape or an elliptic cylindrical shape that is corresponding to a shape complementary to an end face portion of a honeycomb structure is formed; and a shallow box-like tray pack that surrounds from the outside and contains at least one tray of these two trays, and in a usage mode, in the two trays, the upper end face portions and the lower end face portions of the honeycomb structures are contained and the honeycomb structures are secured; and on the side of the lower end face portion, further, the honeycomb structures are contained in the tray pack as are in the tray. Therefore, on the occasion when the honeycomb structure is put in or taken out, it is a packaging body that is not a box the access to which is limited to at the top and that a lateral access can be made, so that an automation using a general-purpose robot arm and hand is easily achieved.

In specific, in packaging of a honeycomb structure using the first packaging body for a honeycomb structure according to the present invention, first a shallow box-like tray pack is placed and one tray is put therein. Subsequently, the lower end face portion of the honeycomb structures is contained in a pocket of the tray. For example, using a general-purpose robot arm and hand, the honeycomb structure is held as is standing at the peripheral faces, moved in a horizontal direction as it is (that is, a lateral access is made), moved to above the pocket of the tray, and thereafter released, thereby enabling to put the lower end face portion of the honeycomb structure in the pocket. Furthermore, one more tray is put on the upper end face portions of the honeycomb structures, and as is necessary, the whole is secured using e.g., a band, thus to complete the packaging of the minimum construction.

In addition, to take the honeycomb structure having been packaged as mentioned above out of the first packaging body for a honeycomb structure according to the present invention, it can be made in the reverse procedure. First, the band and the like having been used for securing is untied and removed, and thereafter from the upper end face portions of the honeycomb structures, one tray is removed. Thus, the honeycomb structures in the standing state that are contained at their lower end face portions in the pockets in another tray appear, for example, a general-purpose robot arm and hand is used and made to approach with respect to the honeycomb structure from side (the side of the peripheral face of the honeycomb structure) (that is, a lateral access is made), the honeycomb structure is held at the peripheral face and lifted a little, and taken out of the pocket of the tray at the lower end face portion and thereafter moved in a horizontal direction, thereby enabling to take out the honeycomb structure.

In the first packaging body for a honeycomb structure according to the present invention, two trays and a tray pack are to be a minimum component, and as compared to a conventional packaging box to be manufactured of materials such as plastics or corrugated cardboards, the amount used of materials is reduced. Furthermore, it is a matter of course that also the amount of wastes after a packaging body has been used and its life has reached the end is decreased as compared to a conventional case.

In the first packaging body for a honeycomb structure according to the present invention, the honeycomb structures are firmly secured by the two trays in which a pocket is formed and the honeycomb structures are contained in the tray pack as are in the tray to which they are secured, so that the honeycomb structures having been packaged are easy to be transported, as well as highly stable during transportation.

The second packaging body for a honeycomb structure according to the present invention is the one which comprises two trays in which a pocket having a cylindrical shape or an elliptic cylindrical shape that is corresponding to a shape complementary to the end face portion of a honeycomb structure, and in which these two trays are brought in engagement by having a mode of the above-mentioned (1) or (2), and in a usage mode, in the two trays brought in mutual engagement, the upper end face portions and the lower end face portions of the honeycomb structures are contained to secure the honeycomb structures; and preferably on the side of the lower end face portion, further, the honeycomb structures are contained in the pallet as are in the tray, and the tray and the pallet are also brought in engagement. Therefore, on the occasion when the honeycomb structure is put in or taken out, it is a packaging body that is not a box the access to which is limited to at the top and that a lateral access can be made, so that an automation using a general-purpose robot arm and hand is easily achieved.

In specific, in packaging of a honeycomb structure using the second packaging body for a honeycomb structure according to the present invention, first, preferably a pallet is placed and one tray is disposed thereon. Subsequently, the lower end face portion of the honeycomb structures is contained in a pocket of the tray. For example, using a general-purpose robot arm and hand, the honeycomb structure is held as is standing at the peripheral faces, moved in a horizontal direction as it is (that is, a lateral access is made), moved to above the pocket of the tray, and thereafter released, thereby enabling to put the lower end face portion of the honeycomb structure in the pocket. Furthermore, one more tray is put on the upper end face portions of the honeycomb structures, and as is necessary, the whole is secured using e.g., a band, thus to complete the packaging of the minimum construction.

In addition, to take the honeycomb structure having been packaged as mentioned above out of the second packaging body for a honeycomb structure according to the present invention, it can be made in the reverse procedure. First, the band and the like having been used for securing is untied and removed, and thereafter from the upper end face portions of the honeycomb structures, one tray is removed. Thus, the honeycomb structures in the standing state that are contained at their lower end face portions in the pockets in another tray appear, for example, a general-purpose robot arm and hand is used and made to approach with respect to the honeycomb structure from side (the side of the peripheral face of the honeycomb structure) (that is, a lateral access is made), the honeycomb structure is held at the peripheral face and lifted a little, and taken out of the pocket of the tray at the lower end face portion and thereafter moved in a horizontal direction, thereby enabling to take out the honeycomb structure.

In the second packaging body for a honeycomb structure according to the present invention, two trays that are brought in engagement are to be a minimum component, preferably there is provided a pallet, and as compared to a conventional packaging box to be manufactured of materials such as plastics or corrugated cardboards, the amount used of materials is reduced. Furthermore, it is a matter of course that also the amount of wastes after a packaging body has been used and its life has reached the end is decreased as compared to a conventional case.

In the second packaging body for a honeycomb structure according to the present invention, the honeycomb structures are firmly secured by the two trays in which a pocket is formed, the trays having secured the honeycomb structures are brought in mutual engagement, and further the honeycomb structures having been secured between the two trays are mounted on a pallet that is engaged with the tray. Therefore, the honeycomb structures having been packaged are easy to be transported, as well as highly stable during transportation. The reason is no occurrence of shifting of trays and pallets during transportation.

The packaging body for a honeycomb structure acting to package a honeycomb structure according to the present invention, in its preferred mode, further comprises a protective member to surround from the side the tray and the honeycomb structures having been packaged, so that the honeycomb structures having been packaged, during transportation or storing, as is the case in which a packaging body is a box, are protected and unlikely to be damaged.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating an embodiment of a first packaging body for a honeycomb structure according to the present invention.

FIG. 2 is a perspective view illustrating, with a partially perspective internal part, the state in which a honeycomb structure is packaged using the packaging body for a honeycomb structure illustrated in FIG. 1.

FIG. 3 is a perspective view illustrating another embodiment of a first packaging body for a honeycomb structure according to the present invention.

FIG. 4 is a perspective view illustrating, with a partially perspective internal part, the state in which a honeycomb structure is packaged using a packaging body for a honeycomb structure illustrated in FIG. 3.

FIG. 5 is a perspective view illustrating still another embodiment of a first packaging body for a honeycomb structure according to the present invention.

FIG. 6 is a perspective view illustrating, with a partially perspective internal part, the state in which a honeycomb structure is packaged using a packaging body for a honeycomb structure illustrated in FIG. 5.

FIG. 7 is a view illustrating an embodiment of a second packaging body for a honeycomb structure according to the present invention, and a partly perspective side view.

FIG. 8 is a plan view of a tray forming a packaging body for a honeycomb structure illustrated in FIG. 7.

FIG. 9 is a side view of a tray forming a packaging body for a honeycomb structure illustrated in FIG. 7.

FIG. 10 is a plan view of another tray forming a packaging body for a honeycomb structure illustrated in FIG. 7.

FIG. 11 is a side view of another tray forming a packaging body for a honeycomb structure illustrated in FIG. 7.

FIG. 12 is a plan view of a pallet forming a packaging body for a honeycomb structure illustrated in FIG. 7.

FIG. 13 is a view illustrating another embodiment of a second packaging body for a honeycomb structure according to the present invention, and a partly perspective side view.

FIG. 14 is a view illustrating still another embodiment of a second packaging body for a honeycomb structure according to the present invention, and a partly perspective side view.

FIG. 15 is a view illustrating still another embodiment of a second packaging body for a honeycomb structure according to the present invention, and a partly perspective side view.

DESCRIPTIONS OF REFERENCE NUMERALS

-   1, 31, 51: tray -   2. 32. 52: tray pack -   4: honeycomb structure -   4 a: upper end face portion (of a honeycomb structure) -   5, 35, 55: pocket -   6, 36, 56: (normal) pallet -   7: cover -   8, 38, 48: water-proof and drip-proof member -   10, 50: band -   11, 61: protective member -   20, 40, 60: packaging body for a honeycomb structure -   70, 130, 140, 150: packaging body for a honeycomb structure -   101, 102, 131, 132, 141, 142, 151, 152: tray -   105. 135, 145, 155: pocket -   106, 136, 146, 156: pallet -   107, 137, 147, 153, 157: convex part -   108, 138, 144, 148, 154, 158: concave part -   109, 139, 149, 159: fork insertion hole

DESCRIPTION OF THE PREFERRED EMBODIMENT

Hereinafter, a preferred embodiment according to the present invention will be described referring to the drawings as appropriate, but the present invention should not be interpreted to be limited to these embodiments. In the scope in which essentials according to the present invention are not impaired, based on knowledge of persons skilled in the art, various changes, modifications, improvements and substitutions can be added. For example, the drawings illustrate a preferred embodiment according to the present invention, but the present invention is not limited to the mode illustrated in the drawings or information shown in the drawings. To carry out or to examine the present invention, means similar to the one that is described in the present specification or means equivalent thereto can be applied, but preferred means is means described as follows.

First, FIGS. 1 and 2 are perspective views illustrating a preferred embodiment of a first packaging body for a honeycomb structure according to the present invention. In FIG. 1, illustrated is one set of two bodies of honeycomb structures 4 and a packaging body 20 for a honeycomb structure that can package two bodies of the honeycomb structures 4. Furthermore, in FIG. 2, illustrated with a partly perspective internal part is the state in which six sets of the packaging bodies 20 for a honeycomb structure that are illustrated in FIG. 1 are used per one layer, these sets are stacked in three layers, and a total of 36 bodies (=2×6×3) of honeycomb structures 4 are packaged.

The packaging body 20 for a honeycomb structure that is illustrated in FIG. 1 can be stacked in multiple layers as is illustrated in FIG. 2. The packaging body 20 for a honeycomb structure includes two trays 1 (one set) and one shallow box-like tray pack 2. Each of the two trays 1 is a tray that is made of, for example, polypropylene functioning to support and secure two bodies of honeycomb structures 4 at their upper end face portions and lower end face portions, and is formed with two pockets 5 having a shape complementary to an end face portion (upper end face portion and lower end face portion) of the honeycomb structure 4.

The tray pack 2 is a tray that is made of, for example, a corrugated cardboard functioning to surround from the outside and to contain the tray 1 on the side of the lower end face portion (in FIG. 1) of the honeycomb structure 4 of the two trays 1.

Packaging of 36 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 2, using 18 sets of the packaging bodies 20 for a honeycomb structure, is done as follows. The following works can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structure 4 is put in the tray 1, a lateral access can be made.

First, on the occasion of stacking in three layers using the packaging body 20 for a honeycomb structure, there is disposed a cover 7 (refer to FIG. 2) to be disposed in the lowermost layer of the stacked laminate. The cover 7 is a platy body that is made of, for example, a corrugated cardboard, and can additionally be disposed on the uppermost face of the stacked laminate and between the layers. Next, on the cover 7 to be in the lowermost layer, six tray packs 2 for the first layer are disposed, and further, the tray 1 is put in each of the tray packs 2. In addition, 12 bodies of honeycomb structures 4 for the first layer are put in the trays 1 so that their lower end face portions are contained in the pockets 5, and thereafter, the trays 1 are put on so that their upper end face portions are held in the pockets 5. Thus, the packaging in the first layer is ended.

In the second layer and thereafter, stacking is made as is in the first layer. That is, on the trays 1 on the side of the upper end face portion of the honeycomb structure 4 in the first layer, the cover 7 for between the first layer and the second layer is disposed, on the cover 7, six tray packs 2 for the second layer are disposed, further the tray 1 is put in each of the tray packs 2, 12 bodies of honeycomb structures 4 for the second layer are put in the trays 1 so that their lower end face portions are contained in the pockets 5, and thereafter the trays 1 are put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 5. Thus, the stacking in the second layer is ended. Furthermore, on the trays 1 on the side of the upper end face portion of the honeycomb structure 4 in the second layer, the cover 7 for between the second layer and the third layer is disposed, on this cover 7, six tray packs 2 for the third layer are disposed, further the tray 1 is put in each of the tray packs 2, 12 bodies of honeycomb structures 4 for the third layer are put in the trays 1 so that their lower end face portions are contained in the pockets 5, and thereafter, the trays 1 are put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 5. Thus, the stacking in the third layer is ended.

Thereafter, using a platy protective member 11 that is made of, for example, a corrugated cardboard, the laminate of three stacks is surrounded at the side faces (refer to FIG. 2). Furthermore, the cover 7 is disposed on the upper most face of the laminate, further, the cover 7 at the uppermost face (as is necessary, also the above-mentioned protective member 11 on the side faces), is covered with a water-proof and water-drip member 8 that is, for example, a film made of polyethylene, and the entire laminate of three stacks are tied up using a band 10 to be secured. In addition, in case where the laminate that is tied up using the band 10 is mounted on a (normal) pallet 6 that is made of, for example, veneer, packaging of three stacks as is illustrated in FIG. 2 that is preferred to be stored for a predetermined period in a storehouse or to be transported from the storehouse to a predetermined place will be completed.

Next, FIGS. 3 and 4 are perspective views illustrating another embodiment of the first packaging body for a honeycomb structure according to the present invention. In FIG. 3, illustrated is one set of 12 bodies of honeycomb structures 4 and a packaging body 40 for a honeycomb structure that can package 12 bodies of these honeycomb structures 4. Furthermore, in FIG. 4, illustrated with a partially perspective internal part is the state in which one set of the packaging body 40 for a honeycomb structure is used per one layer, these sets are stacked in three layers, and a total of 36 bodies (=12×1×3) of honeycomb structures 4 are packaged.

The packaging body 40 for a honeycomb structure illustrated in FIG. 3 is the one that can be stacked in multiple layers as is illustrated in FIG. 4. The packaging body 40 for a honeycomb structure includes two sets of trays 31 (trays) (four trays, and one tray is omitted in FIG. 3), and two (one set of) shallow box-like tray packs 32. Each of the two trays 31 is a tray that is made of, for example, polyethylene functioning to support and secure six bodies of honeycomb structures 4 at their upper end face portions 4 a and lower end face portions, and formed with six pockets having a shape that is complementary to an end face portion (upper end face portion 4 a and lower end face portion) of the honeycomb structure 4.

There are provided in one set of the packaging body for a honeycomb structure two tray packs 32 of the one that contains the trays 31 (surrounding from the outside) on the side of the lower end face portion of the honeycomb structure 4 (in FIG. 3), and the one that is put on the trays 31 (put on from the outside) on the side of the upper end face portion 4 a of the honeycomb structure 4. The tray pack 32, as is the already-described tray pack 2, is a tray that is made of, for example, a corrugated cardboard. In one tray pack 32 illustrated in FIG. 3 can contain two trays 31.

Packaging of 36 bodies of honeycomb structures 4 in a form stacked in multiple layers as is illustrated in FIG. 4, using three sets of the packaging bodies 40 for a honeycomb structure, is done as follows. The following works can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structure 4 is put in the tray 31, a lateral access can be made.

First, in the packaging body 40 for a honeycomb structure, the tray pack 32 in the first layer is disposed. Subsequently, two trays 31 are put in the tray pack 32. Next, 12 bodies of honeycomb structures 4 for the first layer are put respectively six bodies in one tray 31 so that their lower end face portions are contained in the pockets 35, thereafter one tray 31 is put on six bodies of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets, and a total of two trays 31 are put on. Thereafter, further on the two trays 31 having been put on the honeycomb structures 4, one tray pack 32 is put on. Thus, the stacking in the first layer is ended.

In the second layer and thereafter, the stacking is made as is in the first layer. That is, on the tray pack 32 having been put on the side of the upper end face portion 4 a of the honeycomb structure 4 in the first layer, the tray pack 32 in the second layer is disposed. Further, two trays 31 are put in this tray pack 32, thereafter 12 bodies of honeycomb structures 4 for the second layer are put respectively six bodies in one tray 31 so that their lower end face portions are contained in the pockets 35, further, one tray 31 is put on six bodies of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets 5, and a total of two trays 31 are put on. Thereafter, further on the two trays 31 having been put on the honeycomb structures 4, one tray pack 32 is put on. Thus, the stacking in the second layer is ended. Subsequently, on the tray pack 32 having been put on the side of the upper end face portion 4 a in the honeycomb structure 4 in the second layer, the tray pack 32 in the third layer is disposed. Further, the two trays 31 are contained in this tray pack 32, thereafter, 12 bodies of honeycomb structures 4 for the third layer are put respectively six bodies in one tray 31 so that their lower end face portions are contained in the pockets 35, further, one tray 31 is put on six bodies of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets 35, and a total of two trays 31 are put on. Thereafter, further on the two trays 31 having been put on the honeycomb structures 4, one tray pack 32 is put on. Thus, the stacking in the third layer is ended.

Thereafter, the entire laminate of three stacks is covered with a water-proof and drip-proof member 38 that is, for example, a film that is made of polyethylene (refer to FIG. 4). Further, in case where the laminate that is covered with the water-proof and drip-proof member 38 is mounted on a (normal) pallet 36 that is made of, for example, veneer, the packaging in three stacks as is illustrated in FIG. 4 that is preferred to be stored in a predetermined period in a storehouse or to be transported from the storehouse to a predetermined place will be completed. Incidentally, in a mode of the packaging illustrated in FIG. 4, the entire laminate of three stacks is not tied up using a band, but only secured only by the water-proof and drip-proof member 38 (stretch film) functioning as a joining member.

Next, FIGS. 5 and 6 are perspective views illustrating still another embodiment of the first packaging body for a honeycomb structure according to the present invention. In FIG. 5, illustrated is one set of 16 bodies of honeycomb structures 4 and a packaging body 60 for a honeycomb structure that can package 16 bodies of these honeycomb structures 4. In addition, in FIG. 6, illustrated with a partly perspective internal part is the state in which one set of the packaging body 60 for a honeycomb structure illustrated in FIG. 5 is used, these sets are stacked in three layers, and a total of 48 bodies (=16×1×3) of honeycomb structures 4 are packaged.

The packaging body 60 for a honeycomb structure illustrated in FIG. 5 is the one that can be stacked in multiple layers as is illustrated in FIG. 6. The packaging body 60 for a honeycomb structure includes four sets (eight trays, three trays are omitted in FIG. 5) of trays 51 (trays) and two (one set of) shallow box-like tray packs 52 (tray packs). Each of the two trays 51 is a tray that is made of, for example, polyethylene functioning to support and secure 4 bodies of honeycomb structures 4 at their upper end face portions 4 and lower end face portions, and is formed with four pockets 55 having a shape that is complementary to the end face portion (upper end face portion 4 a and lower end face portion) of the honeycomb structure 4.

There are provided in one set of the packaging body 60 for a honeycomb structure two tray packs 52 of the one that contains the trays 51 (surrounding from the outside) on the side of the lower end face portion of the honeycomb structure 4 (in FIG. 5) and the one that is put on the trays 51 (put from the outside) on the side of the upper end face portion 4 a of the honeycomb structure 4. The tray pack 52 is a tray that is made of, for example, a corrugated cardboard as is the above-described tray pack 2, 32. One tray pack 52 illustrated in FIG. 5 can contain four trays 31.

Packaging of 48 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 6, using three sets of the packaging bodies 60 for a honeycomb structure, is done as follows. The following works can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structure 4 is put in the tray 51, a lateral access can be made.

First, in the packaging body 60 for a honeycomb structure, the tray pack 52 in the first layer is disposed. Subsequently, four trays 51 are put in the tray pack 52. Next, 16 bodies of honeycomb structures 4 for the first layer are put respectively four bodies in one tray 51 so that their lower end face portions are contained in the pockets 55, thereafter, one tray 51 is put on four bodies of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets 5, and a total of four trays 51 are put on. Thereafter, further one tray pack 52 is put on the four trays 51 having been put on the honeycomb structures 4. Thus, the stacking in the first layer is ended.

In the second layer and thereafter, the stacking is made as is in the first layer. That is, on the tray pack 52 having been put on the side of the upper end face portion 4 a of the honeycomb structures 4 in the first layer, the tray pack 52 for the second layer is disposed. Subsequently, four trays 51 are contained in this tray pack 52, thereafter, 16 bodies of honeycomb structures 4 for the second layer are put respectively four bodies in one tray 51 so that their lower end face portions are contained in the pockets 55, further, one tray 51 is put on four pieces of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets 5, and a total of four trays 51 are put on. Thereafter, further, one tray pack 52 is put on the four trays 51 having been put on the honeycomb structures 4. Thus, the stacking in the second layer is ended. Furthermore, on the tray pack 52 having been put on the side of the upper end face portion 4 a of the honeycomb structures 4 in the second layer, the tray pack 52 for the third layer is disposed. Subsequently, four trays 51 are put in this tray pack 52, thereafter, 16 bodies of honeycomb structures 4 for the third layer are put respectively four bodies in one tray 51 so that their lower end face portions are contained in the pockets 55, further, one tray 51 is put on four bodies of honeycomb structures 4 respectively so that their upper end face portions 4 a are held in the pockets 55, and a total of four trays 51 are put on. Thereafter, further, one tray pack 52 is put on the four trays 51 having been put on the honeycomb structures 4. Thus, the stacking in the third layer is ended.

Thereafter, using a platy protective member 61 that is made of, for example, a corrugated cardboard, the laminate of three stacks is surrounded at the side faces (refer to FIG. 6). Further, the uppermost face of the laminate is covered with a water-proof and drip-proof member 48 that is a film made of, for example, polyethylene, and the entire laminate of three stacks is tied up and secured using a band 50. In addition, in case where the laminate having been tied up using the band 50 is mounted on a (normal) pallet 56 that is made of, for example, veneer, the packaging of three stacks as is illustrated in FIG. 6 that is preferred to be stored for a predetermined period in a storehouse or to be transported from the storehouse to a predetermined place will be completed.

Incidentally, in the above descriptions of the embodiments of the first packaging body for a honeycomb structure according to the present invention, after the honeycomb structures are packaged to be a laminate of three stacks using a tray or a tray pack, as is illustrated in FIGS. 2, 4 and 6, the laminate is brought in a packaging form that is preferred to be transported using a protective member, a water-proof and drip-proof member and a pallet; while, after the laminate of three stacks has been obtained, the whole thereof can be mounted on a box-like pallet, for example, Palletainer(R: Registered trademark) to be transported.

Now, FIGS. 7 to 12 are perspective views illustrating an embodiment of a second packaging body for a honeycomb structure according to the present invention. In FIG. 7, illustrated is one set of 64 bodies of honeycomb structures 4 and a packaging body 70 for a honeycomb structure that can package 64 bodies of these honeycomb structures 4. FIG. 8 is a plan view of a tray 101 forming the packaging body 70 for a honeycomb structure, and FIG. 9 is a side view of the same tray 101. FIG. 10 is a plan view of a tray 102 forming the packaging body 70 for a honeycomb structure, and FIG. 11 is a side view of the tray 102. FIG. 12 is a plan view of a pallet 106 forming the packaging body 70 for a honeycomb structure. FIG. 7 is a partly perspective side view, so that only 16 bodies of honeycomb structures 4 of ¼ the total thereof are illustrated.

The packaging body 70 for a honeycomb structure, as is illustrated in FIG. 7, is the one in which the trays 101 and 102 can be stacked in multiple layers. In FIG. 7, the trays 101 and 102 are stacked in five layers, and the honeycomb structures 4 are stacked in four layers therebetween. The packaging body 70 for a honeycomb structure includes one pallet 106, eight (four/one layer×two layers) trays 101 in contact with the top face of the pallet 106 (in FIG. 7), and twelve (four/one layer×three layers) trays 102. Incidentally, although it is omitted in FIG. 7, further on the top of the four trays (what appear in FIG. 7, being the side view, are two trays) on the upper side in FIG. 7, one pallet 106 can be disposed as is on the lower side.

Each of the trays 101 and 102, as is illustrated in FIGS. 8 and 10, is a tray that is made of, for example, polypropylene functioning to support and secure four bodies of honeycomb structures 4 at their upper end face portions and lower end face portions, and is formed with four pockets 105 in one face having a shape that is complementary to the end face portion (upper end face portion and lower end face portion) of the honeycomb structure 4. The tray 101, to be in contact with the pallet 106 at one face, is provided with four convex parts 107 on the face to be contacted with this pallet 106, and formed with four pockets only in the other face. Whereas, there are formed in the tray 102 four pockets 105 at either face.

The pallet 106 includes a fork insertion hole 109 so as to be usable for loading and unloading using a forklift, as well as 16 numbers of concave parts 108, Furthermore, one pallet 106 is joined to the four trays 101, and four concave parts 108 loosely fitted to four convex parts 107 of one tray 101 respectively.

Packaging of 64 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 7, using one set of the packaging body 70 for a honeycomb structure, is done as follows. First, the pallet 106 is placed in a predetermined position. The following works can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structures 4 is put in the trays 101 and 102, a lateral access can be made.

Next, on the pallet 106 to be in the lowermost layer, four trays 101 of the first layer are disposed. At this time, four convex parts 107 of each tray 101 are loosely fit to the concave parts 108 of the pallet 106, and the pallet 106 and the tray 101 are brought in engagement. Further, 16 bodies of honeycomb structures 4 for the first layer are put respectively four bodies in one tray 101 so that their lower end face portions are contained in the pockets 105. Thereafter, the tray 102 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 105. Thus, the stacking in the first layer is ended.

In the second layer and thereafter, the stacking is made as is in the first layer. That is, 16 bodies of honeycomb structures 4 for the second layer are put respectively four bodies in one tray 102 so that their end face portions are contained in the pockets 105 that are formed in the face on the side (on the top) of the tray 102 opposite to the side of the upper end face portion of the honeycomb structure 4 in the first layer. Thereafter, the tray 102 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 105. Thus, the stacking in the second layer is ended. Furthermore, 16 bodies of honeycomb structures 4 for the third layer are put respectively four bodies in one tray 102 so that their lower end face portions are contained in the pockets 105 that are formed in the face on the side (on the top) of the tray 102 opposite to the side of the upper end face portion of the honeycomb structure 4 in the second layer. Thereafter, the tray 102 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 105. Thus, the stacking in the third layer is ended. In addition, 16 bodies of honeycomb structures 4 for the fourth layer are put respectively four bodies in one tray 102 so that their lower end face portions are contained in the pockets 15 that are formed in the face on the side (on the top) of the tray 102 opposite to the side of the upper end face portion of the honeycomb structure 4 in the third layer. Thereafter, the tray 101 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 105. Thus, the stacking in the fourth layer is ended.

Thereafter, as the need arises, it is preferable that further, one more pallet 106 to be in the uppermost layer is put on, and using a platy protective member that is made of, for example, a corrugated cardboard, the laminate of four stacks is surrounded at the sides or the laminate is covered with a water-proof and drip-proof member that is a film made of, for example, polyethylene. Due to the fact that the pallet 106 and the tray 101 in the lowermost layer are fit to each other, cargo shifting is prevented. Therefore, it is unnecessary to tie up the entire laminate of four stacks using a band. Thus, the packaging of four stacks that is preferred to be stored in a storehouse for a predetermined period or to be transported from the storehouse to a predetermined place will be completed.

Now, FIG. 13 is a perspective view illustrating another embodiment of the second packaging body for a honeycomb structure according to the present invention. In FIG. 13, is illustrated one set of 9 bodies of honeycomb structures 4 and a packaging body 130 for a honeycomb structure that can package 9 bodies of these honeycomb structures 4. FIG. 13 is a partly perspective side view, but all the honeycomb structures 4 are illustrated.

The packaging body 130 for a honeycomb structure, as is illustrated in FIG. 13, is the one in which trays 131 and 132 can be stacked in multiple layers. In FIG. 13, there are four layers of the trays 131 and 132, and the honeycomb structures 4 are stacked in three layers therebetween. The packaging body 130 for a honeycomb structure includes one pallet 136, two (one/one layer×two layers) trays 131 that are contacted with the top face of the pallet 136 (in FIG. 13), and two (one/one layer×two layers) trays 132. Incidentally, although it is omitted in FIG. 13, further on the top of the tray 131 on the upper side in FIG. 13, one more pallet 136 can be disposed as is on the lower side.

Each of the trays 131 and 132 are a tray that is made of, for example, polypropylene functioning to support and secure three bodies of honeycomb structures 4 at their upper end face portions and lower end face portions, and is formed with three pockets 135 having a shape that is complementary to the end face portion (upper end face portion and lower end face portion) of the honeycomb structure 4 in one face. The tray 131, to be in contact with the pallet 136 at one face, is provided with two convex parts 137 on the face to be contacted with the pallet 136, and formed with three pockets 135 only in the other face. Whereas, there are formed in the tray 132 three pockets 135 at either face.

The pallet 136 is provided with a fork insertion hole 139 so as to be usable for loading and unloading using a forklift, as well as two concave parts 138. Furthermore, the pallet 136 is joined to the tray 131 on one-to-one basis, and with the two concave parts 138, is loosely fit to the two convex parts 137 of the tray 131.

The method of packaging of 9 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 13 is as is the method of the above-described packaging body 70 for a honeycomb structure illustrated in FIG. 7, so that descriptions will be omitted. Likewise, first the pallet 136 is placed in a predetermined position, works thereafter can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structure 4 is put in the trays 131 and 132, a lateral access can be made.

Now, FIG. 14 is a perspective view illustrating still another embodiment of the second packaging body for a honeycomb structure according to the present invention. In FIG. 14, illustrated is one set of 9 bodies of honeycomb structures 4 and a packaging body 140 for a honeycomb structure that can package 9 bodies of these honeycomb structures 4. FIG. 14 is a partly perspective side view, but all the honeycomb structures 4 are illustrated.

The packaging body 140 for a honeycomb structure, as is illustrated in FIG. 14, is the one in which trays 141 and 142 can be stacked in multiple layers. In FIG. 14, there are four layers of the trays 141 and 142, and three layers of honeycomb structures 4 are stacked in three layers therebetween. The packaging body 140 for a honeycomb structure includes one pallet 146, two (one/one layer×two layers) trays 141 that are in contact with the top face of the pallet 146 (in FIG. 14) and two (one/one layer×two layers) trays 142. Incidentally, although it is omitted in FIG. 14, further on the top of the tray 141 on the upper side in FIG. 14, one more tray 146 can be disposed as is on the lower side.

Each of the trays 141 and 142 is a tray that is made of, for example, polypropylene functioning to support and secure three bodies of honeycomb structures 4 at their upper end face portions and lower end face portions, and formed with three pockets 145 having a shape complementary to the end face portion (upper end face portion and lower end face portion) of the honeycomb structure 4 in one face. The tray 141, to be in contact with the pallet 146 at one face, is provided with two convex parts 147 on the face to be contacted with this pallet 146, and formed with three pockets 145 only in the other face. Whereas, there are formed in the tray 142 three pockets 145 at either face. In addition, in the packaging body 140 for a honeycomb structure, the trays 141 and 142 are laminated in close contact with each other. Further, in each of the trays 141 and 142, on the side of the tray 141 facing to the tray 142 and on the side of the tray 142 facing to the tray 141, there are formed two concave parts 144, as well as at each interface where the tray 141 and the tray 142 are in face-to-face contact, there are provided two (a total of six) joining members 143. The joining member 143 is loosely fit in the concave part 144 that is formed in each of the trays 141 and 142, and functions to bring the trays 141 and 142 in engagement.

The pallet 146 is provided with a fork insertion hole 149 so as to be usable for loading and unloading using a forklift, and two concave parts 148. Further, the pallet 146 is joined to the tray 141 on one-to-one basis, and with the two concave parts 148, is loosely fit to the two convex parts 147 of the tray 141.

Packaging of 9 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 14, using one set of the packaging body 140 for a honeycomb structure is done as follows. First, the pallet 146 is placed in a predetermined position. Work thereafter can be fully automated using a general purpose robot arm and hand, and on the occasion in which the honeycomb structure 4 is put in the trays 141 and 142, a lateral access can be made.

Subsequently, on the pallet 146 to be in the lowermost layer, the tray 141 of the first layer is disposed. At this time, the two convex parts 147 of the tray 141 are loosely fit to the concave parts 148 of the pallet 146, and the pallet 146 and the tray 141 are brought in engagement. Furthermore, three bodies of honeycomb structures 4 for the first layer are put in the tray 141 so that their lower end face portions are contained in the pockets 145. Thereafter, the tray 142 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 145. At this time, before the tray 142 is put on, the joining member 143 is loosely fit to the two concave parts 144 of the tray 141, and when the tray 142 is put on, the tray 141 and the tray 142 are brought in engagement so that the joining member 143 is loosely fit to the two concave parts 144 of the tray 142. Thus, the stacking in the first layer is ended.

In the second layer and thereafter, the stacking will be done as is in the first layer. That is, three bodies of honeycomb structures 4 for the second layer are put on so that their lower end face portions are contained in the pockets 145 that are formed in the face on the side (on the top) of the tray 142 opposite to the side of the upper end face portion of the honeycomb structure 4 in the first layer. Thereafter, the tray 142 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 145. At this time, before the tray 142 is newly put on, the joining member 143 is loosely fit to the two concave parts 144 of the tray 142 having been previously located, and when a new tray 142 is put on, the two upper and lower trays 142 are brought in engagement so that the joining member 143 is loosely fit to the two concave parts 144 of this tray 142. Thus, the stacking in the second layer is ended. Furthermore, three bodies of honeycomb structures 4 for the third layer are put on so that their lower end face portions are contained in the pockets 145 that are formed in the face on the side (on the top) of the tray 142 opposite to the side of the upper end face portion of the honeycomb structure 4 in the second layer. Thereafter, the tray 141 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 145. At this time, before the tray 141 is put on, the joining member 143 is loosely fit to the two concave parts 144 of the tray 142 having been previously located, and when the tray 141 is put on, the tray 141 and the tray 142 are brought in engagement so that the joining member 143 is loosely fit to the two concave parts 144 of this tray 141. Thus, the stacking in the third layer is ended.

Thereafter, as the need arises, it is preferable that further, one more pallet 146 to be in the uppermost layer is put on, and using a platy protective member that is made of, for example, a corrugated cardboard, the laminate of three stacks is surrounded at the sides or the laminate is covered with a water-proof and drip-proof member that is a film made of, for example, polyethylene. Due to the fact that the pallet 146 and the tray 141 in the lowermost layer are fit to each other, cargo shifting is prevented. Therefore, it is unnecessary to tie up the entire laminate of three stacks using a band. Thus, the packaging of three stacks that is preferred to be stored in a storehouse for a predetermined period or to be transported from the storehouse to a predetermined place will be completed. Incidentally, the engagement between the pallet 146 and the tray 141, as is the engagement between the tray 141 and 142, may be done via a joining member.

Now, FIG. 15 is a perspective view illustrating still another embodiment of the second packaging body for a honeycomb structure according to the present invention. In FIG. 15, illustrated is one set of 9 bodies of honeycomb structures 4 and a packaging body 150 for a honeycomb structure that can package 9 bodies of these honeycombs structures 4. FIG. 15 is a partly perspective side view, but all the honeycomb structures 4 are illustrated.

The packaging body 150 for a honeycomb structure, as is illustrated in FIG. 15, is the one in which trays 151 and 152 can be stacked in multiple layers. In FIG. 15, there are four layers of the trays 151 and 152, and three layers of honeycomb structures 4 are stacked in three layers therebetween. The packaging body 150 for a honeycomb structure includes one pallet 156, two (one/one layer×two layers) trays 151 in contact with the top face of the pallet 156 (in FIG. 15), and two (one/one layer×two layers) trays 152. Incidentally, although it is omitted in FIG. 15, further on the top of the tray 151 on the upper side in FIG. 15, one pallet 156 can be disposed as is on the lower side.

Each of the trays 151 and 152 are a tray that is made of, for example, polypropylene functioning to support and secure three bodies of honeycomb structures 4 at their upper end face portion and lower end face portion, and is formed with three pockets 155 having a shape that is complementary to the end face portion (upper end face portion and lower end face portion) of the honeycomb structure 4 in one face. The tray 151, to be in contact with the pallet 156 at one face, is provided with two convex parts 157 on the face to be contacted with this pallet 156, and formed with three pockets 155 only in the other face. Whereas, there are formed in the tray 152 three pockets 155 at either face. In addition, in the packaging body 150 for a honeycomb structure, at the tray 151, in addition to the above-mentioned convex parts 157, there are provided two convex parts 153 on the side facing to the tray 152; as well as there are formed on the side of the tray 152 facing to the tray 151 two concave parts 154. The convex parts 153 of the tray 151 are loosely fit to the concave parts 154 of the tray 152, and thus the trays 151 and 152 are brought in engagement.

The pallet 156 is provided with a fork insertion hole 159 so as to be usable for loading and unloading using a forklift, and formed with two concave parts 158. Furthermore, the pallet 156 is joined to the tray 151 on one-to-one basis, and with the two concave parts 158, loosely fit to the two convex parts 157 of the tray 151.

Packaging of 9 bodies of honeycomb structures 4 in a form of stacked in multiple layers as is illustrated in FIG. 15, using one set of the packaging body 150 for a honeycomb structure, is done as follows. First, the pallet 156 is placed in a predetermined position. Works thereafter can be fully automated using a general-purpose robot arm and hand, and on the occasion when the honeycomb structure 4 is put in the trays 151 and 152, a lateral access can be made.

Next, on the pallet 156 to be in the lowermost layer, the tray 151 of the first layer is disposed. At this time, the two convex parts 157 of the tray 151 are loosely fit to the concave parts 158 of the pallet 156, and the pallet 156 and the tray 151 are brought in engagement. Subsequently, three bodies of honeycomb structures 4 for the first layer are put in the tray 151 so that their lower end face portions are contained in the pockets 155. Thereafter, the tray 152 is put on the honeycomb structures 4 so that their upper end face portions are held in the pockets 155. At this time, the tray 151 and the tray 152 are brought in engagement so that the two convex parts 153 of the tray 151 are loosely fit to the two concave parts 154 of the tray 152. Thus, the stacking in the first layer is ended.

In the second layer and thereafter, the stacking will be done as is in the first layer. That is, three bodies of honeycomb structures 4 for the second layer are put on so that their lower end face portions are contained in the pockets 155 that are formed in the face on the side (on the top) of the tray 152 opposite to the side of the upper end face portion of the honeycomb structure 4 in the first layer. Thereafter, the tray 152 is put on the honeycomb structures 4 so that their end face portions are contained in the pockets 155. At this time, the tray 151 and the tray 152 are brought in engagement so that the two convex parts 153 of the tray 151 are loosely fit to the two concave parts 154 of the tray 152. Thus, the stacking in the second layer is ended. Furthermore, three bodies of honeycomb structures 4 for the third layer are put on so that their lower end face portions are contained in the pockets 155 that are formed in the face on the side (on the top) of the tray 152 opposite to the side of the upper end face portion of the honeycomb structure 4 in the second layer. Thereafter, the tray 151 is put on the honeycomb structure 4 so that their upper end face portions are held in the pockets 155. At this time, the tray 151 and the tray 152 are brought in engagement so that the two convex parts 153 of the tray 151 are loosely fit to the two concave parts 154 of the tray 152. Thus, the stacking in the third layer is ended.

Thereafter, as the need arises, it is preferable that further, one more pallet 156 to be in the uppermost layer is put on, and using a platy protective member that is made of, for example, a corrugated cardboard, the laminate of three stacks are surrounded at the sides or the laminate is covered with a water-proof and drip-proof member that is a film made of, for example, polyethylene. Due to the fact that the pallet 156 and the tray 151 in the lowermost layer are fit to each other, cargo shifting is prevented. Therefore, it is unnecessary to tie up the entire laminate of three stacks using a band to be secured. Thus, the packaging of three stacks that is preferred to be stored in a storehouse for a predetermined period or to be transported from the storehouse to a predetermined place will be completed.

Incidentally, in the above descriptions of the embodiments of the second packaging body for a honeycomb structure according to the present invention, although a pallet is used in the lowermost layer (and in the uppermost layer as is necessary), instead of the pallet, for example, a box-like pallet such as Palletainer (R) can be used. In this case, it is unnecessary to be provided with a convex part at a tray to be in the lowermost layer.

Now, the method of manufacturing a packaging body for a honeycomb structure according to the present invention will be described. A tray forming a packaging body for a honeycomb structure according to the present invention, using plastic materials which main component is polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride and the like, can be manufactured by e.g., vacuum forming.

Furthermore, a tray, using polypropylene, polyethylene, polyethylene terephthalate and the like as a main material, can be manufactured by e.g., foaming forming or pasting of members. A specific means for manufacturing is not particularly limited, and manufacturing can be made by a known method. In particular, a tray that is made of foams by foaming forming is further improved in breakage prevention performance owing to its cushioning characteristics and elastic properties.

In addition, a tray, using iron, aluminum or metal and alloy which main component is these ones, can be manufactured by casting.

A tray pack, using paper, particularly a corrugated cardboard or a hard paper, can be manufactured by punching or by pasting of members. A pallet, using wood or paper, can be manufactured by assembly such as pasting.

Furthermore, a tray pack, using plastic materials which main component is polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride and the like, can be manufactured by e.g., injection forming.

INDUSTRIAL APPLICABILITY

A packaging body for a honeycomb structure according to the present invention is preferably used as a packaging means for storing or transporting a honeycomb structure that is made of ceramics for use in a catalyst or a filter for purifying an exhaust gas of automobiles. 

1-11. (canceled)
 12. A packaging body for a honeycomb structure, being a package body for packaging a honeycomb structure having a columnar shape, comprising: at least two trays having a plate shape and in which a pocket having a cylindrical shape or an elliptic cylindrical shape is formed; and a shallow box-like tray pack that surrounds from the outside and contains at least one tray of the at least two trays.
 13. The packaging body for a honeycomb structure according to claim 12, wherein said tray pack can contain a plurality of said trays.
 14. The packaging body for a honeycomb structure according to claim 12, wherein said tray pack is a formed body which material is paper.
 15. The packaging body for a honeycomb structure according to claim 12, wherein at one face or at both faces of said tray having a plate shape, there is formed a plurality of said pockets.
 16. The packaging body for a honeycomb structure according to claim 12, wherein said tray is a formed body which main material is any of polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride, iron and aluminum.
 17. A packaging body for a honeycomb structure, being a package body for packaging a honeycomb structure having a columnar shape, comprising: at least three trays having a plate shape and in which a pocket having a cylindrical shape or an elliptic cylindrical shape is formed at one face or at both faces, wherein a tray having said pocket at one face is disposed in the uppermost layer and in the lowermost layer, and a tray having said pocket at both faces is disposed at an intermediate portion.
 18. The packaging body for a honeycomb structure according to claim 17, further comprising a pallet to be in contact with one face of at least one tray of said trays, wherein the pallet and said one tray are brought in engagement by having a mode in which: (a) there is provided at said pallet a plurality of concave parts or convex parts and there is provided at said one tray a plurality of convex parts or concave parts, and the concave parts and the convex parts of said pallet are loosely fit to the convex parts and the concave parts of said one tray, or (b) there is provided in said pallet and said one tray a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to the concave parts that are formed in said pallet and said one tray.
 19. The packaging body for a honeycomb structure according to claim 17, wherein the two trays of said trays are brought in engagement by having a mode in which; (1) there is formed a plurality of concave parts in one tray of the two trays and there is provided at the other tray a plurality of convex parts, and the concave parts of said one tray and the convex parts of said other tray are brought in a loose fit, or (2) there is provided in each of the two trays a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to said concave parts formed in each of the two trays.
 20. The packaging body for a honeycomb structure according to claim 17, wherein at one face or at both faces of said tray having a plate shape, there is formed a plurality of said pockets.
 21. The packaging body for a honeycomb structure according to claim 17, wherein said tray is a formed body which main material is any of polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride, iron and aluminum.
 22. A packaging body for a honeycomb structure acting to package a honeycomb structure, being a packaging body for packaging a honeycomb structure having a columnar shape, comprising: at least two trays having a plate shape and in which a pocket having a shape complementary to an end face portion of said honeycomb structure is formed at one face, wherein an end face portion of said honeycomb structure is fit in said each pocket of two trays of at least two trays, and a honeycomb structure is packaged; and wherein said two trays are brought in engagement by having a mode in which: (x) there is formed a plurality of concave parts in one tray of the two trays and there is provided at the other tray a plurality of convex parts, and the concave parts of said one tray and the convex parts of said other tray are brought in a loose fit; or (y) there is provided in each of the two trays a plurality of concave parts as well as there is provided a plurality of joining members, and the joining members are loosely fit to said concave parts formed in each of the two trays.
 23. A packaging body for a honeycomb structure acting to package a honeycomb structure according to claim 22, further comprising a protective member surrounding said honeycomb structure and said tray to which an end face portion of the honeycomb structure is fit from the side of said honeycomb structure.
 24. A packaging body for a honeycomb structure acting to package a honeycomb structure according to claim 23, wherein said protective member has a plate shape or a film shape. 